Method and device for monitoring the performance of industrial equipment

ABSTRACT

The invention relates to a method for automatically monitoring the performance of industrial equipment comprising a compressor. According to the inventive method, operating parameters of said industrial equipment, including at least the gas flow (Q) in the compressor, the pressure (P in ) of the gas entering the compressor, the pressure (P out ) of the gas leaving the compression, the temperature (T rEfr ) of the coolant of the compressor, are measured. Automatic calibration subsequently occurs for a calculation rule in order to predict the performance factor and to detect a deterioration of the state of the industrial equipment. The invention can be applied to the production of gas from air.

The invention relates to a method for automatically monitoring the performance of industrial equipment and to a device for implementing this method.

One field of application of the invention is for oxygen production units using one or more air, oxygen or nitrogen compressors to separate the components of air.

By monitoring the performance of the industrial equipment, the maintenance of the latter can be planned and its productivity checked. Thus, it is generally found that the benefits of an industrial equipment optimization project are often reduced to nothing after a few years if there is no monitoring that allows the slightest drift in the operation of this industrial equipment to be detected and corrected.

Thus, the operator of the industrial equipment desires to have an industrial equipment performance indicator that reliably reflects any deterioration in the equipment. Thus, it is necessary to be able to distinguish between deterioration of the industrial equipment and a simple variation in its operating conditions.

Document EP-B 516 534 describes a method of monitoring an apparatus operating under variable conditions, delivering a normalized performance parameter which is, for a gas turbine compressor that drives an alternator supplying an electric power distribution network, an air flow rate or a polytropic efficiency. This method uses a quantified model of the behavior of the apparatus to be monitored, established experimentally from measurements made on the apparatus when it is in a known internal state, for example when it is new. The measurements are made on influence parameters representative of variable conditions of external origin in which the apparatus is made to operate, such as the atmospheric pressure, the ambient temperature, the ambient humidity, the flow rate of a fuel feeding the turbine, the composition of the fuel, the temperature of the fuel, the thermal stabilization state of the turbine with its compressor and the frequency of the electric power distribution network. However, this model is not suitable for monitoring the performance of the aforementioned gas production units. In particular, this method does not allow fine monitoring of a performance factor, such as the energy consumption or the isothermal efficiency of a compressor, this being barely correlated with the aforementioned influence parameters.

The aim of the invention is to obtain a method and a device for automatically monitoring the performance of industrial equipment that alleviate the drawbacks of the prior art.

For this purpose, a first subject of the invention is a method for automatically monitoring the performance of industrial fluid protection equipment comprising a refrigerated compressor during the operation of the industrial fluid protection equipment, in which:

-   -   operating parameters of the industrial equipment are measured         using measurement means, these parameters comprising at least         the flow rate of the gas through the compressor, the pressure of         the gas entering the compressor, the pressure of the gas leaving         the compressor, the temperature of the coolant for the         compressor;     -   a performance factor representative of the operation of the         industrial equipment is calculated, using calculation means,         from the measured parameters and from a calculation rule stored         in storage means; and     -   performance monitoring information as a function of the         calculated performance factor is indicated to a user by         indication means.

Thanks to the invention, information about the actual conditions existing in the industrial equipment, in which the monitoring method is carried out, is automatically indicated to a user. Thus, the method may be easily implemented by nonexperts. The precision obtained in detecting the deterioration of the state of the industrial equipment is as good as, if not better than, that obtained by the known systems.

According to other features of the invention:

-   -   during a calibration step, said operating parameters of the         industrial equipment are automatically measured, using said         measurement means, at least once over the course of time,         measured values of the operating parameters are stored in a         memory and the calculation rule is calibrated as a function of         at least one subset from among the set of measured values of the         operating parameters present in the memory, the calibration step         being able to be retriggered by the user for a new calibration         of said calculation rule;     -   the rule for calculating the performance factor comprises the         calculation of an estimated efficiency η_(est) of the compressor         according to the following equation:         $\eta_{est} = {{A\quad Q} + {B\frac{P_{out}}{P_{i\quad n}}} + {C\quad T_{cool}} + {D_{2}T_{g}} + E}$         in which Q is the flow rate of the gas through the compressor,     -   P_(in) is the pressure of the gas entering the compressor,     -   P_(out) is the pressure of the gas leaving the compressor,     -   T_(cool) is the temperature of the coolant for the compressor,     -   A, B, C, D2 and E are predetermined adjustment parameters, the         temperature T_(g) of the gas entering the compressor being         measured, using measurement means, for the chosen nonzero         adjustment parameter D2;     -   the performance factor corresponds to an estimated energy         consumption P_(est) of the compressor according to the following         equation:         P _(est) =[QRT _(cool) ×ln(P _(out) /P _(in))]/η_(est);     -   the adjustment parameters A, B, C, D2, E are calculated by         linear regression from the at least one subset of measured         values of the operating parameters present in the memory;     -   the calculation rule is determined on the basis of a neural         network, the self-learning of which is achieved on the basis of         the at least one subset of measured values of the operating         parameters present in the memory, the adjustment parameters A,         B, C, D, E disappearing when a neural network is used;     -   the calibration step is carried out on command by the operator,         for example after a compressor maintenance operation;     -   the calculated performance factor is used to trigger an alarm         when the calculated performance factor does not meet the         prescribed conditions.

A second subject of the invention is a device for implementing the method for automatically monitoring the performance of industrial fluid production equipment, characterized in that it comprises means for measuring said operating parameters, means for calculating said performance factor from the calculation rule present in the storage means and from the measurements supplied by the measurement means, and means for indicating performance monitoring information to a user on the basis of the calculated performance factor.

According to one feature, the device includes a calculation rule calibration command means.

The invention will be more clearly understood in the light of the description that follows, given solely by way of nonlimiting example, with reference to the appended drawing in which:

FIG. 1 is a flowchart indicating the principle of operation of the monitoring method and the monitoring device according to the invention in a calibration phase;

FIG. 2 is a flowchart indicating the principle of operation of the monitoring method and the monitoring device according to the invention in a prediction phase; and

FIG. 3 shows schematically the performance monitoring device according to the invention.

In the figures, it is firstly determined, during the prior step E1, whether or not a new calibration setting is required. This inquiry is performed by means of a physical or logic command button 1 on the device, for example in the form of a command key on a computer screen. Actuating the button 1 resets the calibration by passing to steps E2, E3, which will be described below.

The monitoring device 2 is intended to be fitted onto one or more compressors 3 used in the industrial equipment. The compressor 3 comprises a gas inlet 4 and a gas outlet 5, the gas being compressed by a compression means contained in the compressor 3. The compressor 3 is cooled by a cooling circuit 6 through which a coolant, such as water for example, circulates. A pressure sensor 7, called the inlet pressure sensor, is mounted on the inlet 4 in order to measure the pressure of the gas entering the compressor 3. A flow rate sensor 8 is mounted on the inlet 4 in order to measure the flow rate of the gas entering the compressor 3. Of course, the sensor 8 may also be mounted on the outlet 5 in order to measure the flow rate of the emerging gas, instead of being mounted on the inlet 4. A sensor 9, called the outlet pressure sensor, is mounted on the outlet 5 in order to measure the pressure of the gas leaving the compressor 3. A temperature sensor 10 is mounted on the cooling circuit 6 in order to measure the temperature of the coolant. A sensor 10 a for measuring the energy consumption of the compressor is also provided, for example a consumed electric power sensor 10 a. If necessary, it is possible to provide an additional sensor 10 b on the inlet 4 of the compressor 3, allowing the temperature T_(g) of the incoming gas to be measured. Also provided on the compressor 3 is a sensor 10 c for detecting the open or closed position Z_(v) of a venting valve.

The sensors 7, 8, 9, 10, 10 a, 10 c and, where appropriate, 10 b are connected to a measurement reception unit 10 d, in which the limits G for each of the measured quantities, for example a maximum threshold S_(max) and a minimum threshold S_(min) for the ranges of values, may be entered. In the measurement reception unit 10 d, the values of the aforementioned parameters, namely the incoming gas pressure P_(in), the gas flow rate Q, the outgoing gas pressure P_(out), the coolant temperature T_(cool), the energy consumption P_(con), the position Z_(v) of the venting valve and, where appropriate, the temperature T_(g) of the incoming gas, which values are received from the sensors 7, 8, 9, 10, 10 a, 10 c, 10 b, are selected using the limits G. The selection is made for example by filtering with respect to the prescribed value limits G for each parameter and by eliminating values that lie outside these limits. These limits are, for example, predetermined ranges of numerical values S_(min) to S_(max), dependent on the sensors 7, 8, 9, 10 a, 10 b and on the compressor 3. The measurement reception unit 10 d includes one or more measurement quality indicators I₁, for example an indicator of the number or percentage of measurements not falling within the limits G.

When the command button 1 has been pressed, the procedure carries out, during the next step E2, the acquisition of measurements of the incoming gas pressure P_(in), the incoming or outgoing gas flow rate Q, the outgoing gas pressure P_(out), the coolant temperature T_(cool), the energy consumption P_(con), the position Z_(v) of the venting valve and, where appropriate, the temperature T_(g) of the incoming gas, these being delivered by the measurement reception unit 10 d from the corresponding sensors 7, 8, 9, 10 a, 10 c, 10 b, in a memory 11 of an automatic calibration unit 11 a. A subset of parameter measurements from among the set of measurements received by the sensors is thus provided by the measurement reception unit 10 d.

The memory 11 is capable of storing, for each parameter P_(in), Q, P_(out), T_(cool), P_(con), Z_(v) and, where appropriate T_(g), several measured values delivered in succession by the measurement reception unit 10 d, for example every hour or at some other frequency. Recorded in the memory 11 are the measurements made at least once over the course of time, and for example regularly over a given period, for example three months. The amount of data used for the calibration, recorded in the memory 11, is limited to the measurements made during a given period, for example one year.

When a sufficient number of measurements have been acquired in the memory 11, or when a prescribed time period has elapsed since the last time that the command button 1 was pressed, parameters for adjusting a predetermined calculation model or rule for a performance factor of the compressor 3 are calculated, during the next step E3, in a first calculation module 12 of the calibration unit 11 a, from the measured parameter or parameters present in the memory 11. As a variant, said parameters for adjusting the predetermined calculation rule for the performance factor of the compressor 3 are calculated on the basis of the last parameter measurements made, which are recorded in the memory 11, and from the previously calculated adjustment parameters by a recursive method, the calibration then being adaptive.

The performance factor is representative of the operation of the industrial equipment and, for example, of the energy consumption of the compressor. The performance factor is for example calculated from a combination of operating parameters P_(in), Q, P_(out), T_(cool) and, where appropriate, T_(g), especially from a linear combination of one or more of the operating parameters.

The performance factor is, for example, calculated in a linear fashion as a function of the ratio of the outgoing gas pressure to the incoming gas pressure P_(out)/P_(in).

In a first embodiment, the calculation rule for the performance factor comprises the calculation of an estimated efficiency η_(est) of the compressor using the following equation (1): $\begin{matrix} {\eta_{est} = {{A\quad Q} + {B\frac{P_{out}}{P_{i\quad n}}} + {C\quad T_{cool}} + {D_{1}.}}} & (1) \end{matrix}$

In another embodiment, the calculation of the performance factor comprises the calculation of an estimated efficiency η_(est) of the compressor using the following equation (2): $\begin{matrix} {\eta_{est} = {{A\quad Q} + {B\frac{P_{out}}{P_{i\quad n}}} + {C\quad T_{cool}} + {D_{2}T_{g}} + {E.}}} & (2) \end{matrix}$

The performance factor corresponds, for example, to an estimated energy consumption P_(est) of the compressor using the following equation (3): P _(est) =[QRT _(cool) ×ln(P _(out) /P _(in))]/η_(est)   (3) where ln denotes the Naperian logarithm.

In equations (1), (2) and (3), A, B, C, D1, D2 and E are the adjustment parameters. These adjustment parameters are calculated during step E3 in the first calculation module 12, for example by linear regression, on the basis of the selected subset of values present in the memory 11, or from the set of values. In this case, such a model is used only when the measurement reception unit 10 d has determined that the position Z_(v) of the venting valve is closed, in order to prevent fluid from passing therethrough.

In another embodiment, the calculation rule for the performance factor is determined using a neural network present in the first calculation module 12. The self-learning of the neural network is carried out on the basis of the subset of selected values in the memory 11 or of the set of values. Using the neural network, either the performance factor Pest is estimated as a function of the explicative parameters Q, P_(out), T_(cool), P_(in), Z_(v) and, where appropriate T_(g), or the performance factor P_(est) is estimated using equation (3), for estimating the efficiency η_(est) as a function of the explicative parameters Q, P_(out), T_(cool), P_(in), Z_(v).

In one embodiment, this neural network serves to partition the space of the explicative parameters, that is to say the aforementioned operating parameters, thereby making it possible to apply a local regression to each region of the space thus partitioned. When the local models have been determined by learning in the calculation module 12, the performance factor is then calculated with reference to these local models.

In another embodiment, the neural network comprises two layers, the first of which is nonlinear and contains a number of neurones close to the number of inputs (for example between three and ten neurones) and the second of which contains the output neurone connected to the first layer.

When the parameters for adjusting the calculation rule for the performance factor, or the performance factor calculation rule itself, have been determined in the first calculation module 12, the rule is stored in storage means 13 of the calibration unit 11 a during step E4.

The storage means 13 are interrogable, in order to deliver the adjustment parameters A, B, C, D1 or A, B, C, D2, E contained therein. Thus, the successive acquisition E2 step, adjustment step E3 and storage step E4 constitute one phase of calibrating the calculation rule for the performance factor.

When the calculation model or rule for the performance factor has been calibrated, the performance factor can be automatically calculated as a function of the operating parameters in a prediction unit 14. It is determined, during step E5 in FIG. 2 whether or not the adjustment parameters present in the means 13 have been transferred to an adjustment parameter backup memory 14 of a prediction unit 15. The calculation module 12 includes one or more calibration quality indicators I₂ in order to allow a user to decide whether he can transfer, during step E5, the model calibrated in the unit 11 a to the prediction unit 15, or whether he must reset the calibration during step E1. For example, the indicator I₂ indicates the mean relative modeling error and/or the number of measurement points used for the calibration. This indicator I₂ may also give an estimate of the value of the detection threshold associated with the calibrated model.

The backup memory 14 is capable of backing up the adjustment parameters that have just been calculated in the calibration unit 11 a and one or more previous versions of these adjustment parameters. A new version of the adjustment parameters is transferred from the storage means 13 to the backup memory 14, during step E6, by acting on a physical or logic command button 16 on the device, for example in the form of a command key on a computer screen. With no transfer of the adjustment parameters present in the means 13 to the backup memory 14, the procedure passes directly to step E7 following step E6.

During step E7, the version of the adjustment parameters that will be received by a calculation module 18, in order to calculate the performance factor, may be selected from the versions of the adjustment parameters that are present in the backup memory 14. For example, stored in the backup memory 14 are the last version and the penultimate version that were calculated from the adjustment parameters in the calibration unit 11 a, in parts 14 a and 14 b thereof. The decision may be made to use either the last version of the adjustment parameters A, B, C, D1 or A, B, C, D1, D2, E during step E8 following step E7, or the old version of the adjustment parameters A, B, C, D1 or A, B, C, D2, E during step E9 following step E7. Storage, during step E8 of a new calculated version of the adjustment parameters in the part 14 a causes the old calculated version of the adjustment parameters to be stored in the part 14 b. The selection of the version of the adjustment parameters is made, for example, under the command of a third physical or logic command button 19 on the device, for example in the form of a command key on a computer screen.

The first, second and third command buttons 11 a, 16, 19 and the input of limits G of the measurement reception unit 10 d are present on a command interface 20 of the device, for example one or more computer screen pages or the like.

The prediction unit receives, during step E10 following steps E8 or E9, the current measurement of the aforementioned operating parameters T_(in), Q, P_(out), T_(cool) and, optionally, T_(g). The same sensors, 7, 8, 9, 10, 10 b are used to measure the operating parameters during the acquisition step E2 in order to enter measurements into the memory 11 of the calibration unit 11 a and during the measurement step E10 for the prediction unit 15. The measurement sensors 7, 8, 9, 10, 10 b are capable of delivering reproducible measurements, that is to say measurement values that are the same for the same operating conditions existing in the compressor 3. Thus, the measurement errors or the biases and offsets inherent in one or more of the sensors 7, 8, 9, 10, 10 b are taken into account right from the calibration so as not to influence, to a great extent, the calculation of the performance factor during the calculation step in the prediction unit 15. The reception unit 10 d for the sensors 7, 8, 9, 10, 10 b is connected in common to the memory 11 and to the prediction unit 14 in order to deliver the measured values of the operating parameters P_(in), Q, P_(out), T_(cool) and, where appropriate T_(g).

The prediction unit 14 includes an interface 17 for receiving the measurements P_(in), Q, P_(out), T_(cool) and, where appropriate, T_(g) that are delivered by the reception unit 10 d for the sensors 7, 8, 9, 10, 10 b.

The storage means 13 and the reception interface 17 are connected to the module 18 for automatically calculating the performance factor as a function of the operating parameters received by the interface 17 and of the calculation rule present in the backup memory 14, during step E11 following step E10.

The performance factor calculated by the calculation module 18 is delivered to user indication means 21, for example of the computer screen type, with digital or other display, in order to be indicated to a user in the form of performance monitoring information, for example the numerical value of the performance factor, during step E12 following step E11.

As a variant or supplement, the calculated performance factor is sent to an alarm trigger module 22 comprising an alarm 23, for example of the audible or message type, triggered when the performance factor calculated by the prediction unit 15 does not satisfy prescribed conditions over a given time. In the above example corresponding to an energy consumption P_(est) as calculated performance factor, these prescribed trigger conditions correspond, for example, to the fact that the difference between or the ratio of the actual energy consumption P_(con) of the compressor and the estimated energy consumption P_(est) exceeds a prescribed energy consumption threshold P_(threshold), the alarm trigger module 22 having for this purpose a comparator 24 that receives, during step E13 following step E11, the calculated performance factor P_(est) coming from the prediction unit 15, the measured actual energy consumption value P_(con) coming from the measurement reception unit 11 a and the energy consumption threshold P_(threshold) that may be prescribed via a corresponding input. During step E14 following step E13, the comparator 24 causes the alarm 23 to be triggered in the event of the threshold P_(threshold) being exceeded.

The calculation module 18 includes one or more quality indicators I₃ of the model used by the prediction unit 15, for example an indicator of the age of the model or of the mean relative prediction error with respect to the quantities involved in the alarm trigger module 22. The indicator or indicators I₃ help the user to decide, should it be necessary, during step E7, to choose the old version or the new version of the calculated model.

The quality indicators I₁, I₂, I₃ are linked to the command interface 20 of the device so as to be able to be presented to the user.

The calibration unit 11 a, the memory 11, the first calculation module 12, the storage means 13, the prediction unit 15, the backup memory 14, the reception interface 17, the calculation module 18 and the indication means 21 may be employed by any technical means, for example electronic or computing means, such as a programmed computer.

The calibration and performance-factor calculation phases may be carried out locally on the site of the compressor or remotely, the calibration unit 11 a, the prediction unit 15, the indication means 21, the alarm trigger module 22 and the command interface 20 all being provided in this case remote from the compressor and being connected to the other elements via a telecommunication network. Thus, the calibration unit 11 a, the prediction unit 15, the indication means 21, the alarm trigger module 22 and the command interface 20 may be provided in a system for centralizing several sites for receiving data in a database. The result of the performance calculation is accessible both locally and remotely.

Thanks to the invention, it is possible to monitor the performance of a compressor with an instrumentation reduced to the minimum necessary for calculating the performance factor or indicator. In particular, it is unnecessary to know the design parameters of the compressor, such as the characteristic curves thereof. The monitoring method and device according to the invention make it possible for any deterioration appearing in the compressor to be detected without requiring precise instrumentation. The method and the device according to the invention make it possible to optimize the compressor maintenance operations and to determine, judiciously, the moment when these operations have to be carried out or if no maintenance operation is to be carried out, thanks to the monitoring of the calculated performance factor. The maintenance costs are thereby reduced, while the productivity of the industrial equipment may thereby be increased, by detecting any deterioration thereof sufficiently early. This allows the maintenance operations to be triggered before further aggravation of the deterioration is observed. The calibration steps E2, E3, E4, E5 in the calibration unit are for example carried out after a maintenance operation. At the same time, the monitoring method and device according to the invention factor out parameters that are not significant with regard to the performance of the compressor. 

1-10. (canceled)
 11. A method which may be used for automatically monitoring the performance of industrial equipment, during the operation of said equipment, comprising the steps of: a) measuring the operating parameters of said equipment with a measurement means, wherein said operating parameters comprise: 1) the flow rate of a gas through said equipment; 2) the pressure of said gas entering said equipment; 3) the pressure of said gas exiting said equipment; 4) the temperature of said gas entering said equipment; and 5) the temperature of a coolant for said equipment; b) calculating, with a calculating means, a performance factor representative of the operation of said equipment, wherein said calculating means uses said measured operating parameters and a calculating rule stored in a storage means; and c) indicating to a user, with an indicating means, performance monitoring information wherein said information comprises a function of said calculated performance factor.
 12. The method of claim 11, wherein said equipment comprises a refrigerated compressor.
 13. The method of claim 11, further comprising a calibration step wherein said calibration step comprises: a) automatically measuring said operating parameters with said measurement means at least once; b) storing said measured operating parameters in a memory means; and c) calibrating said calculation rule as a function of at least one said measured operating parameter located in said memory means.
 14. The method of claim 13, wherein said calibration step is capable of being reinitiated by a user for a new calibration of said calculation rule.
 15. The method of claim 11, wherein said rule for calculating said performance factor comprises a calculation of an estimated efficiency η_(est) of said equipment according to the equation: $\eta_{est} = {{A\quad Q} + {B\frac{P_{out}}{P_{i\quad n}}} + {C\quad T_{cool}} + {D_{2}T_{g}} + E}$ wherein: a) Q represents said flow rate of said gas through said equipment; b) P_(in) represents said pressure of said gas entering said equipment; c) P_(out) represents said pressure of said gas leaving said equipment; d) T_(cool) represents said temperature of said coolant for said equipment; e) A, B, C, and E represent predetermined adjustment parameters; f) D₂ represents a non-zero, predetermined adjustment parameter; and g) T_(g) represents the measured temperature of said gas entering said equipment, as measured by said measurement means.
 16. The method of claim 15, wherein said performance factor corresponds to an estimated energy consumption P_(est) of said equipment, according to the following equation: P _(est) =[QRT _(cool) ×ln(P _(out) /P _(in))]/η_(est)
 17. The method of claim 16, wherein said R represents the Universal Gas Constant.
 18. The method of claim 16, further comprising calculating said adjustment parameters, by linear regression, from at least one of said measured operating parameters present in said memory means.
 19. The method of claim 16, further comprising determining said calculation rule with a neural network means, wherein the self-learning of said neural network means is achieved on the basis of at least one of said measured operating parameters present in said memory.
 20. The method of claim 15, wherein said calibration step is carried out on command by a user.
 21. The method of claim 11, further comprising triggering an alarm when said calculated performance factor does meet prescribed conditions.
 22. An apparatus which maybe used for automatically monitoring the performance of industrial equipment, during the operation of said equipment, wherein: a) said apparatus comprises: 1) a means for measuring the operating parameters of said equipment, wherein said operating parameters comprise: i) the flow rate of a gas through said equipment; ii) the pressure of said gas entering said equipment; iii) the pressure of said gas exiting said equipment; iv) the temperature of said gas entering said equipment; and v) the temperature of a coolant for said equipment; 2) a means for storing a calculation rule; 3) a means for calculating a performance factor representative of the operation of said equipment from said calculation rule stored in said storage means and from said measured operating parameters; and 4) a means for indicating information for monitoring the performance of said equipment; and b) said automatically monitoring the performance of said industrial equipment comprises: 1) measuring said operating parameters with said measurement means; 2) calculating, with said calculating means, said performance factor; and 3) indicating, with said indication means, performance monitoring information to a user wherein said information comprises a function of said calculated performance factor.
 23. The apparatus of claim 22, further comprising a means to initiate a calculation rule calibration, wherein said calculation rule calibration comprises: a) automatically measuring said operating parameters with said measuring means at least once; b) storing said measured operating parameters in a memory means; and c) calibrating said calculation rule as a function of at least one said measured operating parameter located in said memory means. 